Method for manufacturing a plastic web for the production of a trim panel

Abstract

A method for manufacturing a plastic web includes a step of hot extrusion of thermoplastic particles. The thermoplastic particles comprise polyolefin particles that are selected from: thermoplastic polyolefin (TPO) particles; thermoplastic vulcanized polyolefin (TPV) particles; thermoplastic elastomer polyolefin (TPE) particles; and a mixture of all or some of these particles. A quantity of polyolefin particles is between 50% and 96% by weight, relative to a total weight of thermoplastic particles, the polyolefin particles being at least partially derived from recycled materials.

1 . A method for manufacturing a plastic web comprising:
 a step of hot extrusion of thermoplastic particles;   the thermoplastic particles comprising polyolefin particles, the polyolefin particles being selected from: thermoplastic polyolefin (TPO) particles; thermoplastic vulcanized polyolefin (TPV) particles; thermoplastic elastomer polyolefin (TPE) particles; and a mixture of all or some of these particles;   a quantity of polyolefin particles being between 50% and 96% by weight, relative to a total weight of thermoplastic particles,   the polyolefin particles being at least partially derived from recycled materials,   the method being characterized in that:   in a case where the polyolefin particles comprise thermoplastic polyolefin (TPO) particles, a melt flow index (MFI) of the thermoplastic polyolefin particles is between 0.3 g and 10 g/10 min;   in a case where the polyolefin particles comprise thermoplastic vulcanized polyolefin (TPV) particles, the melt flow index (MFI) of the thermoplastic vulcanized particles is between 10 g and 30 g/10 min; and   in a case where the polyolefin particles comprise thermoplastic elastomer polyolefin (TPE) particles, a hardness of the thermoplastic elastomer polyolefin particles is between 45 and 65 Shore A.   
     
     
         2 . The method according to  claim 1 , wherein, prior to the step of hot extrusion, the method comprises a treatment step, wherein the polyolefin particles are subjected to a flow of air at a temperature of between 50° C. and 150° C. 
     
     
         3 . The method according to  claim 1 , wherein the polyolefin particles comprise thermoplastic polyolefin (TPO) particles. 
     
     
         4 . The method according to  claim 1 , wherein the thermoplastic particles further comprise polypropylene (PP) particles, an amount of said polypropylene particles being between 5% and 40% by weight with respect to a total weight of the thermoplastic particles. 
     
     
         5 . The method according to  claim 1 , wherein the thermoplastic particles further comprise low-density polyethylene (LDPE) particles, an amount of said low-density polyethylene particles being between 15% and 30% by weight with respect to a total weight of the thermoplastic particles, said LDPE particles having a melt flow index between 0.3 g and 12.0 g/10 min, and a density between 0.80 and 0.95 g/cm 3 . 
     
     
         6 . A plastic web produced by a method according to  claim 1 . 
     
     
         7 . The plastic web according to  claim 6 , having a thickness of between 0.2 mm and 1.5 mm and/or a density of at least 0.8 g/cm 3 . 
     
     
         8 . A vehicle trim panel, comprising a substrate, a first support layer and a second protective layer, the first support layer being arranged between the substrate and the second protective layer, the first support layer being formed from a plastic web according to  claim 6 . 
     
     
         9 . The vehicle trim panel according to  claim 8 , wherein the second protective layer has a thickness of between 5 μm and 50 μm. 
     
     
         10 . The vehicle trim panel according to  claim 8 , wherein the second protective layer is formed from a material of a polyurethane (PU) or thermoplastic polyurethane (TPU) type, an acrylic, or a mixture of these compounds. 
     
     
         11 . The vehicle trim panel according to  claim 8 , further comprising: a third layer of polyolefin foam, arranged between the first support layer and the substrate. 
     
     
         12 . The vehicle trim panel according to  claim 11 , further comprising a fourth layer arranged between the third layer of polyolefin foam and the substrate, said fourth layer being made of woven or non-woven textile. 
     
     
         13 . The method according to  claim 2 , wherein, in the treatment step, the thermoplastic particles are subjected to a flow of air at a temperature of between 50° C. and 150° C. 
     
     
         14 . The method according to  claim 2 , wherein, in the treatment step, the thermoplastic particles are subjected to a flow of air at a temperature of between 100° C. and 120° C. 
     
     
         15 . The method according to  claim 2 , wherein, in the treatment step, the polyolefin particles are subjected to a flow of air at a temperature of between 100° C. and 120° C. 
     
     
         16 . The method according to  claim 3 , wherein the thermoplastic polyolefin (TPO) particles are mixed with thermoplastic vulcanized polyolefin (TPV) particles and/or thermoplastic elastomer polyolefin (TPE) particles. 
     
     
         17 . The method according to  claim 4 , wherein the PP particles are at least partially derived from recycled materials. 
     
     
         18 . The method according to  claim 4 , wherein the thermoplastic particles further comprise low-density polyethylene (LDPE) particles having a melt flow index between 0.5 g and 12.0 g/10 min, and a density between 0.80 and 0.95 g/cm 3    
     
     
         19 . The method according to  claim 5 , wherein the LDPE particles are at least partially derived from recycled materials.